Absorbent core, articles comprising said core, and methods of making

ABSTRACT

An absorbent core comprising substantially continuous zones of one or more high fluid distribution structures and discontinuous zones of fluid absorption structures surrounding the one or more high fluid distribution structures, wherein the one or more high fluid distribution structures are arranged to distribute fluid across the absorbent core at a speed that is faster than the speed of fluid distribution across the absorbent core by said discontinuous fluid absorption structures, and wherein said continuous zones extend along a path that is substantially parallel to at least a portion of the perimeter of the core, said portion of the perimeter of the core comprising at least a portion of the sides of the core and one of the ends of the core.

TECHNICAL FIELD

The disclosure pertains to the technical field of absorbent hygieneproducts. In particular, the present disclosure relates to an absorbentcore that can be used within an article for absorbing body fluids andexudates, such as urine and fecal material, or blood, menses, andvaginal fluids. More particularly, the present disclosure relates toabsorbent garments, such as disposable diapers or diaper pants,disposable incontinence diapers or pants, and which are configured tocollect and contain fecal material and avoid leakage, or sanitarynapkins or panty liners, which are configured to collect and containblood, menses, urine, vaginal fluids and avoid leakage.

BACKGROUND

The disclosure relates to an absorbent core for an absorbent article, inparticular for hygiene articles, to absorbent articles comprising saidabsorbent core and to processes for providing said absorbent core. Inparticular to cores having one or more channels therethrough.

Absorbent cores have been subject to considerable improvement andinnovation over time to address needs such as improved fluid absorptionand distribution, as well as comfort, and a need for continuedimprovement exists. Such needs are ever present in today's demandingconsumer environment. The following paragraphs elucidate on some of therelevant disclosures pertaining to this subject.

EP 1077052 A1 and EP 1078617 A2 disclose a sanitary napkin allowingcontrolled deformation in response to lateral compression when in use.The sanitary napkin has preferential bending zones extending along alongitudinal axis formed by a process of perforating, slitting, cuttingor embossing.

EP 1959903 B1 discloses an incontinence pad comprising a pair of foldinglines dividing the absorbent core material into a central portion and apair of longitudinal side portions to adapt better to the body of theuser. The folding lines are formed by compression of the absorbentmaterial.

EP 2211808 B1 discloses an absorbent core comprising an upper absorbentcore and a lower absorbent core. The upper absorbent core comprises foldindications enabling the absorbent core to adopt a predeterminedthree-dimensional shape when subjected to pressure in the widthdirection. The fold indications are cuts or compression lines which door do not extend completely through the upper core.

EP 1349524 B1 discloses a pantiliner comprising at least one fold linedefining a central area and two side areas which allows adjusting thesize of the pantiliner by folding the pantiliner along the fold line.The fold lines are lines of embossing.

EP 1267775 B1 discloses a sanitary pad that conforms to the bodyconfinements. The sanitary pad comprises a forward wide portion and arear narrow portion and at least two fold lines preformed on the upperor lower surface of the narrow portion. The fold lines may be selectedfrom mechanically pressed lines, chemically joined constituents formingthe lines, heat generated lines, laser generated lines, adhesivegenerated lines and/or mechanical vibration generated lines.

EP1088536 A2 discloses a hygiene napkin provided with corrugationsmaking it possible to adapt the hygienic napkin to the user's panties.

U.S. Pat. No. 5,756,039 A discloses an absorbent core comprisingdistinct segments which can be independently displaced by a liftingmember. The lifting member ensures that the top sheet conforms to thewearer's body.

US 2006/0184150 A1 discloses an absorbent core with varying flexibilitythat act as shaping element for improved body fit. The absorbent corecan have lines of reduced bending resistance which are formed by removalof material, e.g. in the form of apertures or slots.

U.S. Pat. No. 6,503,233 B1 discloses an absorbent article comprising acombination of downwardly-deflecting crease lines and anupward-deflecting shaping line to achieve a geometry for improved bodyfit. The crease lines are formed by embossing of the absorbent material.The shaping line is formed by perforation or notching.

US 2015/0088084 A1, discloses a method of making an absorbent structurehaving a three-dimensional topography including placing at least aportion of the absorbent structure between opposed mold surfaces. Atleast one of the mold surfaces has a three-dimensional topography. Thethree-dimensional topography of the mold surface is imparted onto theabsorbent structure so that the absorbent structure has athree-dimensional topography corresponding to the three-dimensionaltopography of the mold surface.

However, there remains a need in the art for improved cores and methodsof making that not only can increase the fluid absorptioncharacteristics of the product but also provides for longer lastingdryness and comfort, as well as providing a perception to the user ofsaid improved characteristics.

The present disclosure aims to resolve at least some of the problemsmentioned above.

The present disclosure aims to provide a novel absorbent core havingchannels particularly designed to improve uniform liquid distributionand comfort; an absorbent article comprising the same; and an effectiveprocess of making such cores in a simplified, reliable, reproducible,and cost-effective manner.

SUMMARY

In one aspect, the disclosure relates to an absorbent core comprisingsubstantially continuous zones of one or more high fluid distributionstructures and discontinuous zones of fluid absorption structuressurrounding the one or more high fluid distribution structures, whereinthe one or more high fluid distribution structures are arranged todistribute fluid across the absorbent core at a speed that is fasterthan the speed of fluid distribution across the absorbent core by saiddiscontinuous fluid absorption structures, and wherein said continuouszones extend along a path that is substantially parallel to at least aportion of the perimeter of the core, said portion of the perimeter ofthe core comprising at least a portion of the sides of the core and oneof the ends of the core.

In a further aspect, the disclosure relates to an absorbent corecomprising: a front portion; a back portion; a crotch portion positionbetween the front portion and the back portion; and a longitudinal axisextending along a length of said core and crossing said front, crotchand back portions, the absorbent core having a width extendingperpendicular to said length and a perimeter comprising at least twoopposing ends and at least two opposing sides positioned between saidends wherein the absorbent core comprises one or more substantiallyinterconnected channels extending through at least a portion of thecrotch portion along the length of the core and along at least a portionof said width of the core from one side of the core to the other,preferably said one or more substantially interconnected channels beingsymmetric or asymmetric about the longitudinal axis.

In a preferred aspect, the absorbent core has at least one of theinterconnected channels, preferably each said channel, forming a shapehaving a closed end in the form of a U-bend, and preferably an open endin the form of two diverging ends or a funnel-shape, preferably whereinthe closed end is positioned proximal to the back portion of theabsorbent core and the open end is positioned proximal to the frontportion of the absorbent core and distal from said closed end.

In a further aspect, the disclosure relates to an absorbent articlecomprising said core, preferably said article being selected fromdisposable diapers or diaper pants; disposable incontinence diapers ordiaper pants; sanitary napkins; or panty liners; and typically whereinthe channels in said core remain visible both before and after use ofthe article, preferably wherein the channels are more visible after usethan before use of the article.

In yet a further aspect, the disclosure relates to the use of anabsorbent core according to the disclosure in an absorbent article, forimproved liquid distribution compared to the same absorbent articlecomprising a core free of substantially interconnected channels.

In yet a further aspect, the disclosure relates to the use of anabsorbent core according to the disclosure in an absorbent article, forproviding a tri-stage fluid distribution comprising a first fluiddistribution at a first speed, a second fluid distribution at a secondspeed and a third fluid distribution at a third speed, said first speedbeing greater or equal to said second speed and said third speed beingless than said first speed and less than or equal to said second speed,preferably wherein the first fluid distribution is driven by thesubstantially interconnected channels, the second fluid distribution isdriven by a three-dimensional absorbent material comprised within thecore, and the third fluid distribution is driven by an amount of superabsorbent polymer dispersed within the three-dimensional absorbentmaterial.

In yet a further aspect, the disclosure relates to a process of makingan absorbent core comprising the steps of: providing a mold comprising a3D insert therein, said 3D insert being the inverse shape of the desiredchannels, wherein substantially the entire surface of the mold is influid communication with an under-pressure source except for the 3Dinsert; applying a first nonwoven web to said mold; applying athree-dimensional absorbent material over at least a portion of saidnonwoven; applying a second nonwoven web directly or indirectly over thethree-dimensional absorbent material; optionally applying a bonding stepto form a laminate comprising said first nonwoven, said second nonwovenand said three-dimensional absorbent material therebetween; optionallyremoving said laminate from the mold to form an absorbent corecomprising channels having the inverse shape of said 3D insert; andwherein at least for the duration of the step of applying athree-dimensional absorbent material, the underpressure source isarranged to provide a vacuum force forcing said three-dimensionalabsorbent material around the 3D insert such to substantially evacuatethe surface thereof from three-dimensional absorbent material and formchannels substantially free of three-dimensional absorbent material.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a diagrammatic top view of an absorbent core according toan embodiment herein.

FIG. 2 shows a diagrammatic top view of an absorbent core according toan embodiment herein.

FIG. 3 shows a diagrammatic top view of an absorbent core according toan embodiment herein.

FIG. 4 shows a diagrammatic top view of absorbent cores according to anembodiment herein and having different geometrical shapes formed byinterconnected channels.

FIG. 5 shows a perspective overview of an absorbent article according toan embodiment herein.

FIG. 6 shows a perspective overview of a product according to anembodiment herein.

FIG. 7 shows a plan view of an absorbent article according to anembodiment herein.

FIG. 8 shows a plan view of an absorbent article according to anembodiment herein.

FIG. 9 shows a perspective overview of an absorbent article according toan embodiment herein.

FIG. 10 shows a perspective overview of a product according to anembodiment herein.

FIG. 11 shows a plan view of an absorbent article according to anembodiment herein.

FIG. 12 shows a plan view of an absorbent article according to anembodiment herein.

FIG. 13 shows a diagrammatic view of an absorbent article according toan embodiment herein.

FIG. 14 shows a diagrammatic view of an absorbent article according toan embodiment herein.

FIG. 15A and FIG. 15B show images of molds comprising a 3D insertaccording to an aspect of the present disclosure.

FIG. 16 illustrates interconnected channels wherein the width variesalong the channels.

FIGS. 17A-D illustrate embodiments of the present invention wherein theabsorbent core is combined with an acquisition and distribution layer.

DETAILED DESCRIPTION

Unless otherwise defined, all terms used in disclosing characteristicsof the disclosure, including technical and scientific terms, have themeaning as commonly understood by one of ordinary skill in the art towhich this disclosure belongs. By means of further guidance, termdefinitions are included to better appreciate the teaching of thepresent disclosure.

As used herein, the following terms have the following meanings:

“A”, “an”, and “the” as used herein refers to both singular and pluralreferents unless the context clearly dictates otherwise. By way ofexample, “a compartment” refers to one or more than one compartment.

“About” as used herein referring to a measurable value such as aparameter, an amount, a temporal duration, and the like, is meant toencompass variations of +/−20% or less, preferably +/−10% or less, morepreferably +/−5% or less, even more preferably +/−1% or less, and stillmore preferably +/−0.1% or less of and from the specified value, in sofar such variations are appropriate to perform in the discloseddisclosure. However, it is to be understood that the value to which themodifier “about” refers is itself also specifically disclosed.

“Comprise”, “comprising”, and “comprises” and “comprised of” as usedherein are 35 synonymous with “include”, “including”, “includes” or“contain”, “containing”, “contains” and are inclusive or open-endedterms that specifies the presence of what follows e.g. component and donot exclude or preclude the presence of additional, non-recitedcomponents, features, element, members, steps, known in the art ordisclosed therein.

The expression “% by weight” (weight percent), here and throughout thedescription unless otherwise defined, refers to the relative weight ofthe respective component based on the overall weight of the formulation.

The recitation of numerical ranges by endpoints includes all numbers andfractions subsumed within that range, as well as the recited endpoints.

“Absorbent article” refers to devices that absorb and contain liquid,and more specifically, refers to devices that are placed against or inproximity to the body of the wearer to absorb and contain the variousexudates discharged from the body. Absorbent articles include but arenot limited to diapers, adult incontinence briefs, training pants,diaper holders and liners, sanitary napkins and the like, as well assurgical bandages and sponges. Absorbent articles preferably comprise alongitudinal axis and a transversal axis perpendicular to saidlongitudinal axis. The longitudinal axis is hereby conventionally chosenin the front-to-back direction of the article when referring to thearticle being worn, and the transversal axis is conventionally chosen inthe left-to-right direction of the article when referring to the articlebeing worn. Disposable absorbent articles can include a liquid pervioustop sheet, a back sheet joined to the top sheet, and an absorbent corepositioned and held between the top sheet and the back sheet. The topsheet is operatively permeable to the liquids that are intended to beheld or stored by the absorbent article, and the back sheet may or maynot be substantially impervious or otherwise operatively impermeable tothe intended liquids. The absorbent article may also include othercomponents, such as liquid wicking layers, liquid intake layers, liquiddistribution layers, transfer layers, barrier layers, wrapping layersand the like, as well as combinations thereof. Disposable absorbentarticles and the components thereof can operate to provide a body-facingsurface and a garment-facing surface.

An absorbent article, such as a diaper, comprises a front waistbandregion, a back waistband region, an intermediate crotch region whichinterconnects the front and rear waistband regions. When used herein,reference to a “front” portion refers to that part of the absorbentarticle which is generally located on the front of a subject, such as aninfant or adult, when in use. Reference to the “rear” portion refers tothe portion of the absorbent article generally located at the rear ofthe subject, such as an infant or adult, when in use, and reference tothe “crotch” portion refers to that portion which is generally locatedbetween the legs of subject, such as an infant or adult, when in use.The crotch region is an area where repeated fluid surge typicallyoccurs, within the absorbent article assembly.

“Front”, “rear or back”, and “crotch” portions of the absorbent core asused herein typically refer to portions of the absorbent core that areproximal to respective portions of the absorbent article. For example,the “front” portion of the core is that which is most proximal to thefront of the subject when worn, the “rear or back” portion of the coreis that which is most proximal to the rear or back of the subject whenworn, and the “crotch” portion of the core is the middle portion of theabsorbent core between the “front” and “rear or back” portions.

Preferably, a diaper comprises a liquid permeable “top sheet”, a liquidimpermeable “back sheet”, and an “absorbent medium” disposed between thetop sheet and the back sheet. The top sheet, back sheet and theabsorbent medium could be made from any suitable material known to theperson skilled in the art. The top sheet is generally located at or nearthe bodyside surface of the article, while the back sheet is generallylocated at or near the garment-side surface of the article. Optionally,the article may comprise one or more separate layers which are inaddition to the back sheet and are interposed between the back sheet andthe absorbent medium. Top sheet and back sheet are connected orotherwise associated together in an operable manner.

The “absorbent medium” or “absorbent core” or “absorbent body” is theabsorbent structure disposed between the top sheet and the back sheet ofthe absorbent article in at least the crotch region of the absorbentarticle and is capable of absorbing and retaining liquid body exudates.The size and the absorbent capacity of the absorbent medium should becompatible with the size of the intended wearer and the liquid loadingimparted by the intended use of the absorbent article. Further, the sizeand the absorbent capacity of the absorbent medium can be varied toaccommodate wearers ranging from infants through adults. It may bemanufactured in a wide variety of shapes (for example, rectangular,trapezoidal, T-shape, I-shape, hourglass shape, etc.) and from a widevariety of materials. Examples of commonly occurring absorbent materialsare cellulosic fluff pulp, tissue layers, highly absorbent polymers (socalled superabsorbent polymer particles (SAP)), absorbent foammaterials, absorbent nonwoven materials or the like. It is common tocombine cellulosic fluff pulp with superabsorbent polymers in anabsorbent material.

“Acquisition and distribution layer”, “ADL” or “surge managementportion” refers to a sub-layer which preferably is a nonwoven wickinglayer under the top sheet of an absorbent product, which speeds up thetransport and improves distribution of fluids throughout the absorbentcore. The surge management portion is typically less hydrophilic thanthe retention portion, and has the ability to quickly collect andtemporarily hold liquid surges, and to transport the liquid from itsinitial entrance point to other parts of the absorbent structure,particularly the retention portion. This configuration can help preventthe liquid from pooling and collecting on the portion of the absorbentgarment positioned against the wearer's skin, thereby reducing thefeeling of wetness by the wearer. Preferably, the surge managementportion is positioned between the top sheet and the retention portion.

The term “adhesive” as used herein is intended to refer to any suitablehot melt, water or solvent borne adhesive that can be applied to asurface of a film layer in the required pattern or network of adhesiveareas to form the film-nonwoven laminate of the present disclosure.Accordingly, suitable adhesives include conventional hot melt adhesives,pressure-sensitive adhesives and reactive adhesives (i.e.,polyurethane).

As used herein, the term “adhesive bonding” means a bonding processwhich forms a bond by application of an adhesive. Such application ofadhesive may be by various processes such as slot coating, spray coatingand other topical applications. Further, such adhesive may be appliedwithin a product component and then exposed to pressure such thatcontact of a second product component with the adhesive containingproduct component forms an adhesive bond between the two components.

As used herein, an “airformed web” refers to a material comprisingcellulosic fibers such as those from fluff pulp that have beenseparated, such as by a hammermilling process, and then deposited on aporous surface without a substantial quantity of binder fibers present.Airfelt materials used as the absorbent core in many diapers, forexample, are a typical example of an airformed material.

As used herein, an “airlaid web” is a fibrous structure formed primarilyby a process involving deposition of air-entrained fibers onto a mat,typically with binder fibers present, and typically followed bydensification and thermal bonding. In addition to traditional thermallybonded airlaid structures (those formed with non-tacky binder materialpresent and substantial thermally bonded), the scope of the term“airlaid” according to the present disclosure can also include coform,which is produced by combining air-entrained dry, dispersed cellulosicfibers with meltblown synthetic polymer fibers while the polymer fibersare still tacky. Further, an airformed web to which binder material issubsequently added can be considered within the scope of the term“airlaid” according to the present disclosure. Binder can be added to anairformed web in liquid form (e. g., an aqueous solution or a melt) byspray nozzles, direction injection or impregnation, vacuum drawing, foamimpregnation, and so forth. Solid binder particles can also be added bymechanical or pneumatic means.

As used therein, the term “associated” encompasses configurations inwhich top sheet is directly joined to back sheet by affixing top sheetdirectly to back sheet, and configurations wherein top sheet is joinedto back sheet by affixing top sheet to intermediate members which inturn are affixed to back sheet. Top sheet and back sheet can be affixeddirectly to each other by attachment means such as an adhesive, sonicbonds, thermal bonds or any other attachment means known in the art. Forexample, a uniform continuous layer of adhesive, a patterned layer ofadhesive, a sprayed pattern of adhesive or an array of separate lines,swirls or spots of construction adhesive may be used to affix top sheetto back sheet. It should be readily appreciated that the above-describedattachment means may also be employed to interconnect and assembletogether the various other component parts of the article describedherein.

The terms “back section” and “rear back section” are used herein assynonyms and refer to the area of the absorbent article which is contactwith the back of the wearer when the absorbent article is worn.

The term “back sheet” refers to a material forming the outer cover ofthe absorbent article. The back sheet prevents the exudates contained inthe absorbent structure from wetting articles such as bedsheets andovergarments which contact the disposable absorbent article. The backsheet may be a unitary layer of material or may be a composite layercomposed of multiple components assembled side-by-side or laminated. Theback sheet may be the same or different in different parts of theabsorbent article. At least in the area of the absorbent medium the backsheet comprises a liquid impervious material in the form of a thinplastic film, e.g. a polyethylene or polypropylene film, a nonwovenmaterial coated with a liquid impervious material, a hydrophobicnonwoven material, which resists liquid penetration, or a laminate of aplastic film and a nonwoven material. The back sheet material may bebreathable so as to allow vapour to escape from the absorbent material,while still preventing liquids from passing there through. Examples ofbreathable back sheet materials are porous polymeric films, nonwovenlaminates of spunbond and meltblown layers and laminates of porouspolymeric films and nonwoven materials.

The terms “belly section” and “front belly section” are used herein assynonyms and refer to the area of the absorbent article which is contactwith the belly of the wearer when the absorbent article is worn.

The term “blend” means a mixture of two or more polymers while the term“alloy” means a sub-class of blends wherein the components areimmiscible but have been compatibilized.

As used herein, the “body-facing” or “bodyside” surface means thatsurface of the article or component which is intended to be disposedtoward or placed adjacent to the body of the wearer during ordinary use,while the “outward”, “outward-facing” or “garment-side” surface is onthe opposite side, and is intended to be disposed to face away from thewearer's body during ordinary use. Such outward surface may be arrangedto face toward or placed adjacent to the wearer's undergarments when theabsorbent article is worn.

“Bonded” refers to the joining, adhering, connecting, attaching, or thelike, of at least two elements. Two elements will be considered to bebonded together when they are bonded directly to one another orindirectly to one another, such as when each is directly bonded tointermediate elements.

The term “breathable” refers to films having a water vapor transmissionrate (WVTR) of at least 300 grams/m²-24 hours.

“Carded web” refers to webs that are made from staple fibers that aresent through a combing or carding unit, which opens and aligns thestaple fibers in the machine direction to form a generally machinedirection-oriented fibrous nonwoven web. The web is then bonded by oneor more of several known bonding methods. Bonding of nonwoven webs maybe achieved by a number of methods; powder bonding, wherein a powderedadhesive or a binder is distributed through the web and then activated,usually by heating the web and adhesive with hot air; pattern bonding,wherein heated calendar rolls or ultrasonic bonding equipment are usedto bond the fibers together, usually in a localized bond pattern, thoughthe web can be bonded across its entire surface if so desired;through-air bonding, wherein air which is sufficiently hot to soften atleast one component of the web is directed through the web; chemicalbonding using, for example, latex adhesives that are deposited onto theweb by, for example, spraying; and consolidation by mechanical methodssuch as needling and hydroentanglement.

As used herein, the term “cellulosic” is meant to include any materialhaving cellulose as a major constituent, and specifically comprising atleast 50 percent by weight cellulose or a cellulose derivative. Thus,the term includes cotton, typical wood pulps, nonwoody cellulosicfibers, cellulose acetate, cellulose triacetate, rayon, thermomechanicalwood pulp, chemical wood pulp, debonded chemical wood pulp, milkweed, orbacterial cellulose.

“Chassis” refers to a foundational constituent of an absorbent articleupon which the remainder of the structure of the article is built up oroverlaid, e.g., in a diaper, the structural elements that give thediaper the form of briefs or pants when configured for wearing, such asa back sheet, a top sheet, or a combination of a top sheet and a backsheet.

“Coform” as used herein is intended to describe a blend of meltblownfibers and cellulose fibers that is formed by air forming a meltblownpolymer material while simultaneously blowing air-suspended cellulosefibers into the stream of meltblown fibers. The coform material may alsoinclude other materials, such as superabsorbent particles. The meltblownfibers containing wood fibers are collected on a forming surface, suchas provided by a foraminous belt. The forming surface may include agas-pervious material, such as spunbonded fabric material, that has beenplaced onto the forming surface.

“Compression” refers to the process or result of pressing by applyingforce on an object, thereby increasing the density of the object.

The term “consisting essentially of” does not exclude the presence ofadditional materials which do not significantly affect the desiredcharacteristics of a given composition or product. Exemplary materialsof this sort would include, without limitation, pigments, antioxidants,stabilizers, surfactants, waxes, flow promoters, solvents, particulatesand materials added to enhance processability of the composition.

The diaper can comprise “containment flaps” or “barrier cuffs”. Thecontainment flaps are generally thought to be particularly well suitedfor the containment of fecal matter and to prevent the lateral flow ofliquid waste until such time as the liquid waste can be absorbed by theabsorbent article. Many constructions of containment flaps are known.Such containment flaps generally comprise a proximal edge, intended tobe attached to the absorbent article, and an opposite distal edge whichis generally not attached to the absorbent article along at least aportion of its length. An elastic member is generally located adjacentthe distal edge to assist in maintaining the containment flap in anupright condition and in maintaining a sealing relationship between thedistal edge of the containment flap and the body of a wearer during use.The elastic member is generally located between two layers of materialso that the elastic does not come into contact with the body of awearer. The containment flaps may be manufactured from a wide variety ofmaterials such as polypropylene, polyester, rayon, nylon, foams, plasticfilms, formed films, and elastic foams. A number of manufacturingtechniques may be used to manufacture the containment flaps. Forexample, the containment flaps may be woven, non-woven, spunbonded,carded, cast, blown or the like.

The diaper can comprise leg containment gaskets. Leg “containmentgaskets” help prevent leakage of bodily exudates when the wearer exertscompressive forces on the absorbent article. In particular, thestiffness of the leg containment gaskets prevents twisting and bunchingof the leg openings of the absorbent article which can lead to leaks.

In addition, the elasticity and conformability of the leg containmentgaskets ensures that the bodyfacing surface of the leg containmentgaskets provides an adequate seal against the body of the wearer. Thephysical properties of the leg containment gaskets, such as thethickness and stiffness, also function to space the bodyside liner,outer cover and absorbent core away from the wearer's body when in use.As such, void volume is created between the wearer's body and thebodyside liner and absorbent core of the absorbent article to helpcontain body exudates.

A “continuous waistband” can be an elastomeric, cloth-like, nonwovenfibrous material, such as an elastomeric stretch bonded laminate web oran elastomeric meltblown web. By proper selection of materials, thecontinuous waistband can be rendered temporarily elastically inhibited,such as by compression. Once temporarily elastically inhibited, theelastic material, of which waistband is comprised, can be activated,such as by treating with heat, to recover to a state of elasticity.

“Conventional hot-melt adhesive” means a formulation that generallycomprises several components. These components typically include one ormore polymers to provide cohesive strength (e.g., aliphatic polyolefinssuch as poly (ethylene-co-propylene) copolymer; ethylene vinyl acetatecopolymers; styrene-butadiene or styrene-isoprene block copolymers;etc.); a resin or analogous material (sometimes called a tackifier) toprovide adhesive strength (e.g., hydrocarbons distilled from petroleumdistillates; rosins and/or rosin esters; terpenes derived, for example,from wood or citrus, etc.); perhaps waxes, plasticizers or othermaterials to modify viscosity (i.e., flowability) (examples of suchmaterials include, but are not limited to, mineral oil, polybutene,paraffin oils, ester oils, and the like); and/or other additivesincluding, but not limited to, antioxidants or other stabilizers. Atypical hot-melt adhesive formulation might contain from about 15 toabout 35 weight percent cohesive strength polymer or polymers; fromabout 50 to about 65 weight percent resin or other tackifier ortackifiers; from more than zero to about 30 weight percent plasticizeror other viscosity modifier; and optionally less than about 1 weightpercent stabilizer or other additive. It should be understood that otheradhesive formulations comprising different weight percentages of thesecomponents are possible.

The term “density” or “concentration” when referring to the absorbentmaterial, in particular the SAP, of a layer, refers to the amount of theabsorbent material divided by the surface area of the layer over whichthe absorbent material is spread out.

As used herein, the term “diaper” refers to an absorbent articlegenerally worn by infants about the lower torso.

The term “disposable” is used herein to describe absorbent articles thatgenerally are not intended to be laundered or otherwise restored orreused as an absorbent article (i.e., they are intended to be discardedafter a single use and, preferably, to be recycled, composted orotherwise disposed of in an environmentally compatible manner).

As used herein, the term “elastic resistance” describes an elastic forcethat tends to resist an applied tensile force causing a materialprovided therewith to tend to contract to an untensioned configurationin response to a stretching force.

As used herein, the terms “elastic”, “elastomeric”, “elasticity” orderivations thereof are used to describe the ability of variousmaterials and objects comprised of such to reversibly undergodeformation under stress, e.g., become stretched or extended, in atleast one direction when a force is applied to the material and toresume substantially to their original dimensions upon relaxing, i.e.,when the force is released, without rupture or breakage. Preferably, itrefers to a material or composite which can be elongated in at least onedirection by at least 50% of its relaxed length, i.e., elongated to atleast 150% of its relaxed length, and which will recover upon release ofthe applied tension at least 40% of its elongation. Accordingly, uponrelease of the applied tension at 50% elongation, the material orcomposite contracts to a relaxed length of not more than 130% of itsoriginal length. Examples of suitable elastomer materials includepolyether-polyamide block copolymers, polyurethanes, synthetic linearA-B-A and A-B block copolymers, chlorinated rubber/EVA (ethylene-vinylacetate) blends, EPDM (ethylene-propylene diene monomer) rubbers, EPM(ethylene-propylene monomer) rubbers, blends of EPDM/EPM/EVA, and thelike.

The term “elasticized” refers to a material, layer, or substrate that isnaturally non-elastic, but which has been rendered elastic by, forexample, suitably joining an elastic material, layer, or substratethereto.

“Elongation” means the ratio of the extension of a material to thelength of the material prior to the extension (expressed in percent), asrepresented by the following: “Extension” means the change in length ofa material due to stretching (expressed in units of length).

As used herein the term “extensible” means elongatable in at least onedirection, but not necessarily recoverable.

The term “fabrics” is used to refer to all of the woven, knitted andnonwoven fibrous webs.

“Fastening means”, such as tape tab fasteners, are typically applied tothe back waistband region of the diaper to provide a mechanism forholding the diaper on the wearer. Fastening means, such as tape tabfasteners, snaps, pins, belts, hooks, buckles, “hook/mushroom”-and-loopfasteners (e.g. VELCRO®-type fasteners) and the like, may be employedand are typically applied at the lateral, side ends of the backwaistband region of diaper to provide a mechanism for holding the diaperabout the waist of the wearer in a conventional manner. Tape tabfasteners can be any of those well known in the art, and are typicallyapplied to the corners of the diaper. For example, adhesive fasteners,mechanical fasteners, hook-and-loop fasteners, snaps, pins or buckles,may be used alone, or in combination. For example, the fasteners can beadhesive fasteners, which are constructed to releasably adhere to alanding zone patch attached to the front waistband section of the diaperto provide a refastenable adhesive fastening system.

The term “finished” or “final”, when used with reference to a product,means that the product has been suitably manufactured for its intendedpurpose.

The term “flexible” refers to materials which are compliant and whichwill readily conform to the general shape and contours of the wearer'sbody.

As used herein, the term “garment” means any type of apparel which maybe worn. This includes diapers, training pants, incontinence products,surgical gowns, industrial workwear and coveralls, undergarments, pants,shirts, jackets and the like.

Many of the known superabsorbent polymer particles exhibit gel blocking.“Gel blocking” occurs when superabsorbent polymer particles are wettedand the particles swell so as to inhibit fluid transmission to otherregions of the absorbent structure. Wetting of these other regions ofthe absorbent member therefore takes place via a very slow diffusionprocess. In practical terms, this means acquisition of fluids by theabsorbent structure is much slower than the rate at which fluids aredischarged, especially in gush situations. Leakage from the absorbentarticle can take place well before the particles of SAP in the absorbentmember are even close to being fully saturated or before the fluid candiffuse or wick past the “blocking” particles into the rest of theabsorbent member. Gel blocking can be a particularly acute problem ifthe superabsorbent polymer particles do not have adequate gel strengthand deform or spread under stress once the particles swell with absorbedfluid.

The term “graphic” includes, but is not limited to, any type of design,image, mark, figure, codes, words, patterns, or the like. For a productsuch as a training pant, graphics will generally include objectsassociated with little boys and little girls, such as multi-colortrucks, airplanes, balls, dolls, bows, or the like.

“Hydroentanglement process” refers to the manufacturing of nonwovenwebs. The process involves directing a series of water jets towards afibrous web which is supported on a moving porous belt. The water jetspass downwards through the mass of fibres and on making contact with thesurface of the belt, the jets rebound, and break up: the energy releasedcauses entanglement of the mass of fibres.

The term “high-absorbency material” refers to materials that are capableof absorbing at least 10 times their own weight in liquid. Thehigh-absorbency material may comprise absorbent gelling materials, suchas superabsorbent polymers. Superabsorbent polymers are water-swellable,water-insoluble organic or inorganic materials capable of absorbing atleast about 20 times their own weight of an aqueous solution containing0.9 weight percent of sodium chloride. Absorbent gelling materials canbe natural, synthetic and modified natural polymers and materials. Inaddition, the absorbent gelling materials can be inorganic materials,such as silica gels, or organic compounds such as cross-linked polymers.The term “cross-linked” refers to any means for effectively renderingnormally water-soluble materials substantially water insoluble butswellable. Such means can include, for example, physical entanglement,crystalline domains, covalent bonds, ionic complexes and associations,hydrophilic associations, such as hydrogen bonding, and hydrophobicassociations or Van der Waals forces. Examples of synthetic absorbentgelling material polymers include the alkali metal and ammonium salts ofpoly(acrylic acid) and poly (methacrylic acid), poly(acrylamides),poly(vinyl ethers), maleic anhydride copolymers with vinyl ethers andalpha-olefins, poly(vinyl pyrrolidone), poly(vinylmorpholinone),poly(vinyl alcohol), and mixtures and copolymers thereof. Furtherpolymers suitable for use in the absorbent structure include natural andmodified natural polymers, such as hydrolyzed acrylonitrile-graftedstarch, acrylic acid grafted starch, methyl cellulose, carboxymethylcellulose, hydroxypropyl cellulose, and the natural gums, such asalginates, xanthan gum, locust bean gum and the like. Mixtures ofnatural and wholly or partially synthetic absorbent polymers can also beused. Synthetic absorbent gelling materials typically are xerogels whichform hydrogels when wetted. The term “hydrogel”, however, has commonlybeen used to also refer to both the wetted and unwetted forms of thematerial. The high-absorbency material may be in any of a wide varietyof geometric forms. As a general rule, it is preferred that thehigh-absorbency material be in the form of discrete particles. However,the high-absorbency material may also be in the form of fibres, flakes,rods, spheres, needles, spiral or semi-spiral, cubic, rod-like,polyhedral, or the like. Conglomerates of particles of high-absorbencymaterial may also be used. The high-absorbency material may be presentin the absorbent core in an amount of from about 5 to about 100 weightpercent and desirably from about 30 to about 100 weight percent based onthe total weight of the absorbent core. The distribution of thehigh-absorbency material within the different portions of the absorbentcore can vary depending upon the intended end use of the absorbent core.The high-absorbency material may be arranged in a generally discretelayer within the matrix of hydrophilic fibres. Alternatively, theabsorbent core may comprise a laminate of fibrous webs andhigh-absorbency material or other suitable means of maintaining ahigh-absorbency material in a localized area.

A “hook-and-loop fastener” refers to complementary fastening meanshaving a “hook” portion and a “loop” portion and which are refastenable.The term “hook” as used herein refers to any element capable of engaginganother element, the so called “loop” portion. The term “hook” is notlimited to only “hooks” in its normal sense, but rather encompasses anyform of engaging elements, whether unidirectional or bi-directional. Theterm “loop” is likewise not limited to “loops” in its normal sense, butalso encompasses any structure capable of engaging with a “hook”fastener. Examples of “loop” materials are fibrous structures, likenonwoven materials.

The term “hydrophilic” describes fibers or the surfaces of fibers whichare wetted by the aqueous liquids in contact with the fibers. The degreeof wetting of the materials can, in turn, be described in terms of thecontact angles and the surface tensions of the liquids and materialsinvolved. The term “wettable” is meant to refer to a fiber whichexhibits a liquid, such as water, synthetic urine, or a 0.9 weightpercent aqueous saline solution, in air contact angle of less than 90°,whereas “hydrophobic” or “non-wettable” describes fibers having contactangles equal to or greater than 90°.

As used herein, the term “impermeable” generally refers to articlesand/or elements that are substantially not penetrated by aqueous fluidthrough the entire thickness thereof under a pressure of 1.0 kPa orless. Preferably, the impermeable article or element is not penetratedby aqueous fluid under pressures of 3.4 kPa or less. More preferably,the impermeable article or element is not penetrated by fluid underpressures of 6.8 kPa or less. An article or element that is notimpermeable is permeable.

“Integral” is used to refer to various portions of a single unitaryelement rather than separate structures bonded to or placed with orplaced near one another.

“Join”, “joining”, “joined”, or variations thereof, when used indescribing the relationship between two or more elements, means that theelements can be connected together in any suitable manner, such as byheat sealing, ultrasonic bonding, thermal bonding, by adhesives,stitching, or the like. Further, the elements can be joined directlytogether, or may have one or more elements interposed between them, allof which are connected together.

The term “laid-flat state” is intended to refer to the article when itis flattened into a plane or is substantially flattened into a plane andis used in contrast to when the article otherwise positioned, such aswhen the article is folded or shaped in or for use by a wearer.

“Laminate” refers to elements being attached together in a layeredarrangement.

The use of the term “layer” can refer, but is not limited, to any typeof substrate, such as a woven web, nonwoven web, films, laminates,composites, elastomeric materials, or the like. A layer can be liquidand air permeable, permeable to air but impermeable to liquids,impermeable both to air and liquid, or the like. When used in thesingular, it can have the dual meaning of a single element or aplurality of elements.

The crotch portion of the absorbent article preferably comprisesopposite longitudinal side portions which comprise a pair ofelasticized, longitudinally-extending “leg cuffs”. The leg cuffs aregenerally adapted to fit about the legs of a wearer when in use andserve as a mechanical barrier to the lateral flow of body exudates. Legcuffs are elasticized by leg elastics. The diaper further can comprise afront waist elastic and a rear waist elastic. Materials suitable for usein forming leg elastics are known to those skilled in the art.

Exemplary of such materials are strands or ribbons of a polymeric,elastomeric material which are adhered to the diaper at the leg cuffwhile in a stretched position, or which are attached to the diaper whilethe diaper is pleated, such that elastic constrictive forces areimparted to the leg cuff. Examples of suitable elastomer materials thatcan be used include polyether-polyamide block copolymers, polyurethanes,synthetic linear A-B-A and A-B block copolymers, chlorinated rubber/EVA(ethylene-vinyl acetate) blends, EPDM (ethylene-propylene diene monomer)rubbers, EPM (ethylene-propylene monomer) rubbers, blends ofEPDM/EPM/EVA, and the like.

“Liquid” means a nongaseous substance and/or material that flows and canassume the interior shape of a container into which it is poured orplaced.

“Longitudinal” is a direction running parallel to the maximum lineardimension of the article.

The term “meltblown fibers” means fibers formed by extruding a moltenthermoplastic material through a plurality of fine, usually circular,die capillaries as molten threads or filaments into a high velocity gasstream (e.g. air) which attenuates the filaments of molten thermoplasticmaterial to reduce their diameter, which may be to microfiber diameter.In general, meltblown fibers have an average fiber diameter of up toabout 10 microns. After the fibers are formed, the meltblown fibers arecarried by the high velocity gas stream and are deposited on acollecting surface to form a web of randomly disbursed meltblown fibers.

The term “nonelastic” refers to any material which does not fall withinthe definition of “elastic” above

The term “nonwoven fabric or web” means a sheet material having astructure of individual fibers or threads which are interlaid, but notin a regular manner such as occurs with knitting or weaving processes.Nonwoven fabrics or webs have been formed from many processes such asfor example, meltblowing processes, spunbonding processes, and bondedcarded web processes.

“Pant body” refers to a garment that has a waist opening and a pair ofleg openings, similar to shorts, swim wear, or the like. The describedgarment may or may not have a manually tearable side seam.

By the terms “particle”, “particles”, “particulate”, “particulates” andthe like, it is meant that the material is generally in the form ofdiscrete units. The units can comprise granules, powders, spheres,pulverized materials or the like, as well as combinations thereof. Theparticles can have any desired shape such as, for example, cubic,rod-like, polyhedral, spherical or semi-spherical, rounded orsemi-rounded, angular, irregular, etc. Shapes having a large greatestdimension/smallest dimension ratio, like needles, flakes and fibers, arealso contemplated for inclusion herein. The terms “particle” or“particulate” may also include an agglomeration comprising more than oneindividual particle, particulate or the like. Additionally, a particle,particulate or any desired agglomeration thereof may be composed of morethan one type of material.

The term “polymer” generally includes, but is not limited to,homopolymers, copolymers, such as, for example, block, graft, random andalternating copolymers, terpolymers, etc. and blends and modificationsthereof. Furthermore, unless otherwise specifically limited, the term“polymer” shall include all possible geometrical configurations of thematerial. These configurations include, but are not limited to,isotactic, syndiotactic and random symmetries.

By the term “pre-packed” as used herein, is meant that one or moreabsorbent articles are packed in a single unit before being stacked.

“Pulp fluff” or “fluff pulp” refers to a material made up of cellulosefibers. The fibers can be either natural or synthetic, or a combinationthereof. The material is typically lightweight and has absorbentproperties.

“Refastenable” refers to the property of two elements being capable ofreleasable attachment, separation, and subsequent releasablereattachment without substantial permanent deformation or rupture.

The “retention portion” or “liquid absorption layer” is part of theabsorbent medium. This portion may comprise a matrix of hydrophilicfibers, such as a web of cellulosic fluff, mixed with particles ofhigh-absorbency material. In particular arrangements, the retentionportion may comprise a mixture of superabsorbent hydrogel-formingparticles and synthetic polymer meltblown fibers, or a mixture ofsuperabsorbent particles with a fibrous coform material comprising ablend of natural fibers and/or synthetic polymer fibers. Thesuperabsorbent particles may be substantially homogeneously mixed withthe hydrophilic fibers, or may be nonuniformly mixed. For example, theconcentrations of superabsorbent particles may be arranged in anon-step-wise gradient through a substantial portion of the thickness ofthe absorbent structure, with lower concentrations toward the bodysideof the absorbent structure and relatively higher concentrations towardthe outerside of the absorbent structure. The superabsorbent particlesmay also be arranged in a generally discrete layer within the matrix ofhydrophilic fibers. In addition, two or more different types ofsuperabsorbent may be selectively positioned at different locationswithin or along the fiber matrix.

As used herein the term “sheet” or “sheet material” refers to wovenmaterials, nonwoven webs, polymeric films, polymeric scrim-likematerials, and polymeric foam sheeting.

The absorbent article may also contain side panels. The “side panels”can have any shape such as but not limited to square, rectangular,triangular, circular and trapezoidal shape. They can be joined to therespective opposite side portions of the back section, by a knownmethod, such as heat-sealing or adhesive bonding. The side panels mayalso be formed integrally with the back section by projecting andjoining together the respective top sheet and/or back sheet and/orabsorbent medium outward in lugs having the shape of the side panels.Preferably, the side panels are formed by laminating a layer of nonwovenfabric, a layer of thermoplastic film and a layer of elastic material.The layer of elastic material might be sandwiched between the nonwovenfabric layer and the thermoplastic film by adhesive layers. The layer ofnonwoven fabric might be made of natural fibers, synthetic fibers or ablend of natural fibers and synthetic fibers. The layer of thermoplasticfilm might be made of polyethylene or polypropylene.

The term “spunbond fibers” refers to fibers formed by extruding moltenthermoplastic polymers as filaments or fibers from a plurality ofrelatively fine, usually circular, capillaries of a spinneret, and thenrapidly drawing the extruded filaments by an eductive or otherwell-known drawing mechanism to impart molecular orientation andphysical strength to the filaments. The average diameter of spunbondfibers is typically in the range of from 15-60 μm or higher. Thespinneret can either be a large spinneret having several thousand holesper meter of width or be banks of smaller spinnerets, for example,containing as few as 40 holes.

The term “spunbond meltblown spunbond” (SMS) nonwoven fabric as usedherein refers to a multi-layer composite sheet comprising a web ofmeltblown fibers sandwiched between and bonded to two spunbond layers. ASMS nonwoven fabric can be formed in-line by sequentially depositing afirst layer of spunbond fibers, a layer of meltblown fibers, and asecond layer of spunbond fibers on a moving porous collecting surface.The assembled layers can be bonded by passing them through a nip formedbetween two rolls that can be heated or unheated and smooth orpatterned. Alternately, the individual spunbond and meltblown layers canbe pre-formed and optionally bonded and collected individually such asby winding the fabrics on wind-up rolls. The individual layers can beassembled by layering at a later time and bonded together to form a SMSnonwoven fabric. Additional spunbond and/or meltblown layers can beincorporated in the SMS fabric, for examplespunbond-meltblown-meltblown-spunbond (SMMS), etc.

“Staple fibers” refer to commercially available fibers having diametersranging from less than about 0.001 mm to more than about 0.2 mm; theycome in several different forms such as short fibers ranging from about10 to 50 mm in length and long fibers with a length higher than 50 mm,preferably up to 100 mm.

By “stretch”, it is meant that the material has the ability to extendbeyond its original size in at least one dimension when subjected to atensile force (i. e., tension) applied in the direction of thatdimension, without breaking the material. An extension of for example50% means that the material with an initial length of 100 mm has reacheda length of 150 mm. Stretch may be unidirectional, bi-directional, ormulti-directional. The specific stretch properties of a material mayvary along any of the stretch vectors. The term can include elasticmaterials, as well as nonwovens that can be inherently extensible, butnot necessarily in an elastic manner. Such nonwovens can be made tobehave in an elastic manner by bonding them to elastic films.

By “channels”, it is meant that the structure referred to (e.g. theabsorbent core) comprises recessed regions forming visible conduits orpassages typically extending along the longitudinal axis of the core andhaving a depth in a direction perpendicular to said longitudinal axis.By “visible” it is herein intended clearly visible by naked eye andtypically that the channels have a width generally greater than 1 mm,preferably from 5 mm to 50 mm, more preferably from 8 mm to 40 mm, morepreferably from 10 mm to 30 mm, even more preferably from greater than10 mm to less than 25 mm.

By “interconnected”, it is meant that the structure referred to (e.g.the channels) from a substantially continuous path such as from a firstend of a channel to a second end of the same channel.

By “substantially”, it is meant at least the majority of the structurereferred to. For example, with reference to interconnected channels,“substantially interconnected” means that the majority of the channel isinterconnected and generally wherein a direct and continuous path can betraced by starting from one end of the channel towards another end ofthe channel, said ends (also referred to herein as terminal positions)being distal to each other in a width direction of the core and proximalto a portion of the perimeter of the core, preferably the sides thereof.

By “directly over”, it is meant that the feature referred to is placedover the structure referred to such that the two are in direct contactwith each other at least throughout a substantial portion of saidstructure.

By “indirectly over”, it is meant that the feature referred to is placedover the structure referred to but in such a way that the two are not indirect contact with each other at least throughout a substantial portionof said structure. For example, a nonwoven web applied indirectly over athree-dimensional absorbent material comprises a further layer ofmaterial between said nonwoven web and said three-dimensional absorbentmaterial.

Use of the term “substrate” includes, but is not limited to, woven ornonwoven webs, porous films, ink permeable films, paper, compositestructures, or the like.

Superabsorbent materials suitable for use in the present disclosure areknown to those skilled in the art, and may be in any operative form,such as particulate form, fibers and mixtures thereof. Generally stated,the “superabsorbent material” can be a water-swellable, generallywater-insoluble, hydrogel-forming polymeric absorbent material, which iscapable of absorbing at least about 15, suitably about 30, and possiblyabout 60 times or more its weight in physiological saline (e.g. salinewith 0.9 wt % NaCl). The superabsorbent material may be biodegradable orbipolar. The hydrogel-forming polymeric absorbent material may be formedfrom organic hydrogel-forming polymeric material, which may includenatural material such as agar, pectin, and guar gum; modified naturalmaterials such as carboxymethyl cellulose, carboxyethyl cellulose, andhydroxypropyl cellulose; and synthetic hydrogel-forming polymers.Synthetic hydrogel-forming polymers include, for example, alkali metalsalts of polyacrylic acid, polyacrylamides, polyvinyl alcohol, ethylenemaleic anhydride copolymers, polyvinyl ethers, polyvinyl morpholinone,polymers and copolymers of vinyl sulfonic acid, polyacrylates,polyacrylamides, polyvinyl pyridine, and the like. Other suitablehydrogel-forming polymers include hydrolyzed acrylonitrile graftedstarch, acrylic acid grafted starch, and isobutylene maleic anhydridecopolymers and mixtures thereof. The hydrogel-forming polymers may belightly crosslinked to render the material substantially waterinsoluble. Crosslinking may, for example, be by irradiation or covalent,ionic, Van der Waals, or hydrogen bonding. The superabsorbent materialmay suitably be included in an appointed storage or retention portion ofthe absorbent system, and may optionally be employed in other componentsor portions of the absorbent article. The superabsorbent material may beincluded in the absorbent layer or other fluid storage layer of theabsorbent article of the present disclosure in an amount up to about 60%by weight. Typically, the superabsorbent material, when present, will beincluded in an amount of about 5% to about 40% by weight, based on thetotal weight of the absorbent layer.

“Superabsorbent polymer particles” or “SAPs” refer to water-swellable,water-insoluble organic or inorganic materials capable, under the mostfavorable conditions, of absorbing at least about 10 times their weight,or at least about 15 times their weight, or at least about 25 timestheir weight in an aqueous solution containing 0.9 weight percent sodiumchloride. In absorbent articles, such as diapers, incontinent diapers,etc., the particle size is typically ranging between 100 to 800 μm,preferably between 300 to 600 μm, more preferably between 400 to 500 μm.

The term “target zone” refers to an area of an absorbent core where itis particularly desirable for the majority of a fluid insult, such asurine, menses, or bowel movement, to initially contact. In particular,for an absorbent core with one or more fluid insult points in use, theinsult target zone refers to the area of the absorbent core extending adistance equal to 15% of the total length of the composite from eachinsult point in both directions.

“Tension” includes a uniaxial force tending to cause the extension of abody or the balancing force within that body resisting the extension.

As used herein, the term “thermoplastic” is meant to describe a materialthat softens when exposed to heat and which substantially returns to itsoriginal condition when cooled to room temperature.

The term “top sheet” refers to a liquid permeable material sheet formingthe inner cover of the absorbent article and which in use is placed indirect contact with the skin of the wearer. The top sheet is typicallyemployed to help isolate the wearer's skin from liquids held in theabsorbent structure. The top sheet can comprise a nonwoven material,e.g. spunbond, meltblown, carded, hydroentangled, wetlaid etc. Suitablenonwoven materials can be composed of man-made fibres, such aspolyester, polyethylene, polypropylene, viscose, rayon etc. or naturalfibers, such as wood pulp or cotton fibres, or from a mixture of naturaland man-made fibres. The top sheet material may further be composed oftwo fibres, which may be bonded to each other in a bonding pattern.Further examples of top sheet materials are porous foams, aperturedplastic films, laminates of nonwoven materials and apertured plasticfilms etc. The materials suited as top sheet materials should be softand non-irritating to the skin and be readily penetrated by body fluid,e.g. urine or menstrual fluid. The inner coversheet may further bedifferent in different parts of the absorbent article. The top sheetfabrics may be composed of a substantially hydrophobic material, and thehydrophobic material may optionally be treated with a surfactant orotherwise processed to impart a desired level of wettability andhydrophilicity.

“Training pants” are available for use by children in the potty-trainingstage, and are popular with mothers and caretakers. A training panttypically comprises a top sheet, a back sheet, an absorbent mediumbetween the top sheet and the back sheet, and side seams that bondportions of the side edges of the pant together to form waist and legopenings.

As used herein, the term “transverse” or “lateral” refers to a line,axis, or direction which lies within the plane of the absorbent articleand is generally perpendicular to the longitudinal direction.

“Ultrasonic welding” refers to a technology which joins two materials bymelting them with heat generated from ultrasonic oscillation and thenlaminating them together, such that the molten materials flow and fillthe gap between the two unaffected portions of the two materials,respectively. Upon cooling and shaping, the two materials are joinedtogether.

As used herein, the term “water-swellable, water-insoluble” is meant torefer to a material that, when exposed to an excess of water, swells toits equilibrium volume but does not dissolve into the solution. As such,a water-swellable, water-insoluble material generally retains itsoriginal identity or physical structure, but in a highly expanded state,during the absorption of the water and, thus, must have sufficientphysical integrity to resist flow and fusion with neighboring particles.

By the term “wrapping material” as used herein, is meant a bendablematerial, preferably a sheet material of which the thickness is smaller,more preferably much smaller than its width or length, such as a sheet,a film or a foil. In a particularly preferred embodiment, said wrappingmaterial is capable of being rolled up.

Due to the high concentrations of superabsorbent particles, or otherhigh-absorbency material, in the retention portion, there can be anincreased difficulty with regard to containing the high-absorbencyparticles within the retention portion and restricting the movement ormigration of the superabsorbent onto the bodyside of the diaper. Toimprove the containment of the high-absorbency material, the absorbentstructure can include an improved overwrap, such as a “wrap sheet”,placed immediately adjacent and around the retention portion. The wrapsheet is preferably a layer of absorbent material which covers the majorbodyside and outerside surfaces of the retention portion, and preferablyencloses substantially all of the peripheral edges of the retentionportion to form a substantially complete envelope thereabout.Alternatively, the wrap sheet can provide an absorbent wrap which coversthe major bodyside and outerside surfaces of the retention portion, andencloses substantially only the lateral side edges of the retentionportion. Accordingly, both the linear and the inwardly curved portionsof the lateral side edges of the wrap sheet would be closed about theretention portion. In such an arrangement, however, the end edges of thewrap sheet may not be completely closed around the end edges of theretention portion at the waistband regions of the article. The wrapsheet may comprise a multi-element wrapsheet which includes a separatebodyside wrap layer and a separate outerside wrap layer, each of whichextends past all or some of the peripheral edges of the retentionportion. Such a configuration of the wrap sheet can, for example,facilitate the formation of a substantially complete sealing and closurearound the peripheral edges of the retention portion. The bodyside andouterside layers of the wrap sheet may be composed of substantially thesame material, or may be composed of different materials. For example,the outerside layer of the wrap sheet may be composed of a relativelylower basis weight material having a relatively high porosity, such as awet strength cellulosic tissue composed of softwood pulp. The bodysidelayer of the wrap sheet may comprise one of the previously describedwrap sheet materials (for example may comprise a meltblown web composedof meltblown polypropylene fibers or low porosity cellulosic tissue webcomposed of a blend of hardwood/softwood fibers) which has a relativelylow porosity. The low porosity bodyside layer can better prevent themigration of superabsorbent particles onto the wearer's skin, and thehigh porosity, lower basis weight outerside layer can help reduce costs.

Embodiments of the articles and processes according to the disclosurewill now be described. It is understood that technical featuresdescribed in one or more embodiments maybe combined with one or moreother embodiments without departing from the intention of the disclosureand without generalization therefrom.

Absorbent Core

Absorbent cores 101 according to the present disclosure comprise: afront portion 122; a back portion 124; a crotch portion 126 positionbetween the front portion 122 and the back portion 124; and alongitudinal axis extending along a length of said core 101 and crossingsaid front, crotch and back portions 122, 126, 124, the absorbent core101 having a width extending perpendicular to said length and aperimeter comprising at least two opposing ends 102, 103 and at leasttwo opposing sides 104, 105 positioned between said ends 102, 103wherein the absorbent core 101 comprises one or more substantiallyinterconnected channels 106 extending through at least a portion of thecrotch portion 126 (preferably being at least 60%, more preferably atleast 70%, even more preferably at least 80%, of a crotch portion lengthrunning substantially parallel to the longitudinal axis) along thelength of the core and along at least a portion of said width of thecore, typically along and substantially parallel to the longitudinalaxis, and from one side of the core [e.g. a first side 104] to the other[e.g. a second side 105], preferably said one or more substantiallyinterconnected channels 106 being symmetric or asymmetric about thelongitudinal axis. An advantage of such interconnected channelarrangement is that faster immediate distribution of fluid is achievedacross the core versus a core free of such interconnected channels orcores comprising only discontinuous channels. Such contributes to limitover-saturation of the core in the portion of fluid discharge. Withoutwishing to be bound by theory it is believed that the fact that thefluid is distributed across the core and immediately away from the fluiddischarge position, a perception of dryness and skin comfort is providedto the subject, as well as an impression of longer lasting dryness bythe user.

The longitudinal axis of the core referred to herein may besubstantially parallel to the longitudinal direction 48 (as illustratedfor example in FIG. 11 and FIG. 12), and the width of the core or widthaxis of the core referred to herein may be substantially parallel to thelateral direction 49 (as illustrated for example in FIG. 11 and FIG.12).

In an embodiment the one or more interconnected channels are shaped suchto effectively conduct fluid away from a region of discharge, typicallyby forming a shape that has a distance gradient between opposingsurfaces of the interconnected channels, preferably forming afunnel-shaped profile.

In an embodiment, the channels form a geometric shape across theabsorbent core and along a plane extending parallel to the longitudinalaxis of said core, said geometric shape being selected from the groupconsisting of a semi-hourglass-shaped, v-shaped, u-shaped, pie-shaped,and combinations thereof. Wherein “by semi-hourglass-shaped” it isintended an hourglass shape with only a single end, exemplary shapes areshown in FIG. 4.

In an embodiment, the channels comprise, preferably consist of, a firstnonwoven web bonded to a second nonwoven web by one or more adhesives.Preferably, the adhesive is applied in zones across the width of thechannels such to form zones, preferably alternating zones, of differentbonding strength between the nonwoven web laminate. For example thefirst nonwoven web may be bonded to the second nonwoven web on at leastthree zones along the width of the channel. Such arrangement maycomprise a first adhesive zone, a second adhesive zone and a thirdadhesive zone, the second adhesive zone being interposed between thefirst and third adhesive zones along the width of the channel (e.g. atan axis parallel to the core width and perpendicular to the longitudinalaxis of the core) wherein the bonding strength of the second adhesivezone is greater than the bonding strength of the first and thirdadhesive zones. Examples of ways to achieve such stronger bondingstrength in the second zone include using higher amounts of adhesive inthis zone, applying greater mechanical pressure on this zone, orutilizing a different adhesive type, other ways are also contemplatedprovided a stronger adhesion between nonwoven webs results in suchregion.

In an embodiment the bonding strength in the first and third zones isless than the tensile force generated by the absorbent material locatedproximal to the channel upon wetting, such that the first and secondnonwoven webs may separate in said zones; and wherein the bondingstrength in the second zone is greater than the tensile force generatedby the absorbent material located proximal to the channel upon wetting,such that the first and second nonwoven webs may not separate in saidzone upon wetting and typically the swelling of the absorbent material,and rather may remain fixedly joined. An advantage of this arrangementis that in dry conditions a noticeable channel is visible from thetopsheet side of the article and/or core providing broad channels thatare further useful for channeling more fluid particularly atinitial/early discharge. This arrangement then further allows thebonding at the first and third regions to fail upon for example swellingof the SAP such to allow more volume to be available for expansionthereof (and prevent early saturation or non-optimal absorption), withtypically the second zone resisting such expansion and thus providingintegrity of the channels even in wet state.

In a preferred embodiment the first nonwoven web and/or the secondnonwoven web, preferably the second nonwoven web, are elastic nonwovens(e.g. containing an elastic material such as Vistamaxx resin fromExxonMobil, or other suitable polymers capable of imparting elasticityto a nonwoven web). An advantage of this embodiment is that the nonwovenweb better and more easily wraps around the 3D insert upon applicationof a vacuum and permits subsequent joining to the first nonwoven web ata location corresponding to a position of the base of the 3D insert(opposite a protruding apex thereof). This has an advantage of limitingthe formation of fluid collection basins or sinks within the channels.

The cores herein may have a substantially rectilinear perimeter such asillustrated in FIG. 1 and FIG. 2, or may comprise symmetrical concaveportions in the middle portion thereof as illustrated in FIG. 3. In thelatter embodiment, the concave portions may be aligned with and/orpositioned in a crotch portion of the absorbent article such to providebetter ergonomics and fit along the leg of a wearer. In any of thesecore shape embodiments, it is preferred that said cores are symmetric atleast about the longitudinal axis thereof. Irrespective of the coregeometry, it is understood herein that the same or similar channels asdescribed herein may be interchangeably used.

In an embodiment, referring to FIG. 1 to FIG. 3, at least one andpreferably each substantially interconnected channel 106 comprises: afirst channel portion 107 extending substantially along the longitudinalaxis proximal to a first side 104 of the core 101; a second channelportion 108 extending substantially along the longitudinal axis proximalto a second side 105 of the core 101; and

at least one, preferably only one, connecting channel portion 109 influid communication with said first and second channel portions 107,108. An advantage of this arrangement is fast liquid distribution alongmore than one axis of the absorbent core, typically both thelongitudinal axis and the width axis thereof, such to maximize theabsorption capabilities of the absorbent core over its entire surfacearea. Moreover, such geometry improves the folding of the core and thusallows for a better and snug fit onto the subjects skin (with or withoutaddition of further elastics proximal to said channel portions).

Hereby, connecting channel portion (109) of at least one of theinterconnected channels, the connecting channel portion being in fluidcommunication with said first and second channel portions (107, 108),preferably forms said closed end in the form of a U-bend, preferablywherein the first and second channel portions (107, 108) diverge awayfrom the longitudinal axis at least along a portion of theinterconnecting channel (106) typically exiting from the U-bend, therebyat least partially forming a funnel-shaped interconnected channel nearthe closed end.

The first and second channel portions may be substantially linear; orhave a substantially curved profile preferably selected from concave orconvex; or may comprise a combination of said linear and curvedprofiles. In a preferred embodiment, the first and second channelportions are concave in shape and are generally symmetric about at leastthe longitudinal axis.

The first and second channel portions may extend through at least amajority, preferably the entirety, of the length of the crotch portionalong the longitudinal axis and typically run substantially parallel tothe sides of the core forming the perimeter thereof.

In a highly preferred embodiment, each interconnected channel hereincomprises only a single connecting channel portion 109, typicallyforming an apex of the inter connected channel. An advantage of thisembodiment is fast fluid distribution through the core whilst limitingthe risk of blockages that could otherwise result if pockets of wettedareas are rather formed.

Preferably, the connecting channel portion 109 extends substantiallyalong the width of said core 101, preferably forming a closed end withina surface of said core 101 along a plane parallel to the longitudinalaxis, and preferably positioned opposite to an open end formed bynon-connected first and second terminal positions 110, 111 of theinterconnected channel 106, preferably of the first and second channelportions 107, 108 respectively, typically said non-connected first andsecond terminal positions 110, 111 being distal to each other andproximal to the first and second sides 104, 105 of said core 101respectively, even more preferably said terminal positions 110, 111facing away from each other such to form a funnel-shaped geometricalopening therebetween. Without wishing to be bound by theory it isbelieved that such geometry aids to “funnel” and collect more fluidwhere it is needed and quickly and effectively distribute it away fromthe region of collection.

In an embodiment, and preferably in combination with the previousembodiment, the interconnected channel comprises unconnected first (110)and second (111) terminal positions, whereby the first terminal position(110) extends to a first side (104) of the core and/or the secondterminal position (111) extends to a second side (105) of the core, asfor instance illustrated in FIG. 3. Hereby the entire width of theabsorbent core can be covered by the channel, which ensures a betterfluid distribution.

In an embodiment, the closed end is substantially curvilinear in shape,preferably forming a convex shape between the first and second channelportions 107, 108, or is substantially linear in shape, preferablyforming a straight or triangular shape between the first and secondchannel portions 107, 108. The closed end may be formed by theconnecting channel portion 109. An advantage of such shape is increasingthe surface area of contact with neighboring regions ofthree-dimensional absorbent material such to better promote absorptionof the distributed liquid once evacuated from areas of typically highsaturation.

In an embodiment, a first distance (d₁) between the first channelportion 107 and the second channel portion 108, a second distance (d₂)between the first channel portion 107 and the second channel portion108, wherein the first distance (d₁) is proximal to the front portion122 of the core 101 and the second distance (d₂) is proximal to the backportion 124 of the absorbent core 101, and wherein the first distance(d₁) is greater than the second distance (d₂), preferably wherein thefirst distance (d₁) is at least 1.5d₂, more preferably from 1.8d₂ to3d₂. An advantage being the fast and effective fluid distribution fromregions of typically high saturation towards regions of typically lowersaturation.

In an embodiment, the core comprises a first nonwoven web, typically inthe form of a backsheet; a second nonwoven web, typically in the form ofa topsheet; and a three-dimensional absorbent material positionedbetween the first and second nonwoven webs to form an absorbent corelaminate, typically wherein the three-dimensional absorbent materialcomprises a fibrous web typically comprising airlaid fibers, andpreferably comprises a predetermined amount of super absorbent polymerdispersed therethrough.

In a highly preferred embodiment, the interconnected channel 106 issubstantially free of three-dimensional absorbent material, andpreferably also free of super absorbent polymer. Without wishing to bebound by theory it is believed that absorbent materials delay fluiddistribution compared to the effectiveness of such channels, indeed asfluid is absorbed by the absorbent materials they swell and/or saturateeffectively reducing the amount of fluid that could be allowed to traveltherethrough. Eliminating such materials from the channels allows tomaintain a highly efficient fluid distribution system that operatessubstantially independently from the fluid acquisition/absorptionmechanism of the neighboring regions.

In a preferred embodiment, the core comprises a plurality ofsubstantially interconnected channels, preferably arranged in asubstantially concentric manner, an example being shown in FIG. 4E. Anadvantage being the exponential effectiveness in liquid distribution andchannel formation, particularly as neighboring regions become moresaturated or swell.

In an embodiment, as shown in FIGS. 4C and 4D, the core furthercomprises one or more disconnected channels, preferably at least aportion thereof being arranged concentrically to the substantiallyinterconnected channel. An advantage being effective added local uniformfluid distribution. Moreover, it is believed that upon swelling of theneighboring regions to the channels, upon saturation, visual patternsmay be formed that more evidently convey the perception of efficacy ofthe entire core surface for absorption of fluid.

Preferably, the substantially interconnected channels 106 have a regularor irregular depth, said depth being measured on an axis perpendicularto both the longitudinal axis and the axis along the width of the core101, preferably wherein the cross-section of said channels 106 isselected from the group consisting of curved, polygonal or combinationsthereof.

In a preferred embodiment, as illustrated in FIG. 16, the width of theinterconnected channel (106) may vary along the channel. Preferably, thewidth of the channel decreases from the terminal positions (110, 111)towards the connecting channel portion (109). This is illustrated inFIG. 16, wherein the width (210 a) of the channel (106) near the firstterminal position (110) and the width (210 b) of the channel (106) nearthe second terminal position (111) are larger than the width (211 a) ofthe channel (106) in the first channel portion (107) and the width (211b) of the channel (106) in the second channel portion (108), which arelarger than the width (212) of the channel (106) in the connectingchannel portion (109). Such variance of the width of the channelportions leads to faster distribution. Without wishing to be bound bytheory, the inventors believe that the varying width leverages capillaryeffects that better promote liquid transport from the front to the backof the absorbent article.

It is understood that a number of alternative shapes may be used forchannels described herein, examples of which are shown in FIG. 4 andFIG. 16 without departing from the disclosure embodiments describedherein.

The present disclosure further relates to an absorbent core 101comprising substantially continuous zones of one or more high fluiddistribution structures 112 and continuous or discontinuous zones offluid absorption structures 113, 114 surrounding the one or more highfluid distribution structures 112, wherein the one or more high fluiddistribution structures 112 are arranged to distribute fluid across theabsorbent core 101 at a speed that is faster than the speed of fluiddistribution across the absorbent core by said discontinuous fluidabsorption structures 113, 114, and wherein said continuous zones extendalong a path that is substantially parallel to at least a portion of theperimeter of the core 101, said portion of the perimeter of the corecomprising at least a portion of the sides 104, 105, preferably at leasta portion of both of the sides 104, 105, of the core 101 and one of theends 102, 103 of the core 101 (preferably only one end 103), preferablythe end 103 proximal to the back portion 124. Advantages of thisembodiment includes separating absorbent regions of the core with fluiddistribution regions that effectively uniformly distribute fluid acrossthe core surface with a mechanism as described above as well asproviding a visual perception of efficacy.

In an embodiment the fluid distribution structures are shaped such toeffectively conduct fluid away from a region of discharge, typically byforming a shape that has a distance gradient between opposing surfacesof said structures, preferably forming a funnel-shaped profilesubstantially delimited by one or more fluid absorption structures.

In an embodiment, the high fluid distribution structures form ageometric shape across the absorbent core and along a plane extendingparallel to the longitudinal axis of said core, said geometric shapebeing selected from the group consisting of a semi-hourglass-shaped,v-shaped, u-shaped, pie-shaped, and combinations thereof. Wherein “bysemi-hourglass-shaped” it is intended an hourglass shape with only asingle end as for example shown in FIG. 4B.

In a preferred embodiment, the one or more high fluid distributionstructures comprise, preferably consist of, at least two nonwoven websbonded together (for example with an adhesive); and the zones of fluidabsorption structures comprise a three-dimensional absorbent material(such as cellulosic fluff and/or fibrous web typically comprisingairlaid fibers, typically of the cellulosic kind) and/or asuperabsorbent polymer (typically in the form of a plurality of discreteparticles that may be distributed within the three-dimensional absorbentmaterial or directly agglomerated in one or more pockets between atleast two nonwoven webs).

Preferably, said fluid distribution structures comprise substantiallyinterconnected channels as described in the previous embodiments, andthe fluid absorption structures comprise a three-dimensional absorbentmaterial and/or superabsorbent polymer as described in the previousembodiments.

Absorbent Articles

In an aspect of the disclosure, an absorbent article comprises a core asdescribed above. Preferably said article being selected from disposablediapers or diaper pants; disposable incontinence diapers or diaperpants; sanitary napkins; or panty liners; and typically wherein thechannels in said core remain visible both before and after use of thearticle, preferably wherein the channels are more visible after use thanbefore use of the article.

In an embodiment, the absorbent article comprises a topsheet and abacksheet enclosing the core, wherein at least one of the backsheet ortopsheet comprises a color that is different from the color of the core,preferably wherein the backsheet has a color that is different from thecolor of the topsheet and core, such that the channels may be visuallydiscernible from the topsheet side of the article.

The Examples herein provide further embodiments and structural technicalfeatures that may be included (in isolation or combination) in absorbentarticles according to the present disclosure. It is however understoodthat alternative structural features of the absorbent article may beapplied without departing from the inventive scope of the presentdisclosure.

Acquisition and Distribution Layer

One particular preferred component which can be used in absorbentarticles, in combination with the present invention, is an acquisitionand distribution layer (ADL). The ADL is hereby positioned atbody-facing side of the absorbent core, preferably between a topsheetand the absorbent core of the absorbent article, and more preferably inclose proximity or even in good contact with the body-facing side of theabsorbent core. The use of an ADL in combination with the fluiddistribution structures and/or interconnected channels of the presentinvention lead to an extremely good distribution of fluids from adischarge area to the entire absorbent core.

The inventors have found that fluid distribution in embodiments of theabsorbent article according to the present invention which comprise anADL, may depend on the relative size and positioning of the ADL withrespect to the fluid distribution structure, and in particular theinterconnected channels, of the absorbent core.

FIGS. 17A-D illustrate embodiments with an ADL (201) and its relativesize and position with respect to interconnected channels (106). FIG.17A shows an embodiment wherein the ADL (201) covers the full channel(106). Such an arrangement already improves over prior art arrangementsbecause the combined effects of the ADL and interconnected channel leadto a substantial improvement in the distribution of fluids over thecomplete absorbent core. Nevertheless, the inventors have found thatcertain arrangements provide even better improvements in thedistribution of liquids, these arrangements being illustrated in FIGS.17B-D and further discussed below.

FIG. 17B illustrates a preferred embodiment wherein the ADL (201) isnarrower than the interconnected channel (106), and positioned such thatthe first (110) and second (111) terminal positions extend beyond theside edges (202, 203) of the ADL.

FIG. 17C illustrates a preferred embodiment wherein the ADL (201) ispositioned such that the connecting channel portion (109) extends beyonda rear edge (204) of the ADL. The connecting channel portion (109)preferably comprises or has the shape of a U-bend.

FIG. 17D illustrates a preferred embodiment wherein the ADL (201) isnarrower than the interconnected channel (106), and positioned such thatthe first (110) and second (111) terminal positions extend beyond theside edges (202, 203) of the ADL, and wherein the ADL (201) ispositioned such that the connecting channel portion (109) extends beyonda rear edge (204) of the ADL. The connecting channel portion (109)preferably comprises or has the shape of a U-bend.

These arrangements which are illustrated in FIGS. 17B-D, have in commonthat certain extremities of the interconnected channel (106), inparticular the terminal positions (110, 111) and/or the connectingchannel portion (109), are not covered by the ADL and thus are moreintimately exposed to the wearer. Without wishing to be bound by theory,the inventors believe that these extremities are very beneficial in theworking of the interconnected channel (106) in distributing fluids fromthe discharge area towards regions of the absorbent core which aretypically unexposed, or at least not directly exposed, to fluiddischarges. By ensuring that the ADL does not cover some or all of theseextremities, it is believed that fluid in-flow and/or fluid out-flow forthe interconnected channel is maximized. Furthermore, these embodimentsallow to use a smaller ADL, and thus less raw material, in the absorbentarticle.

Methods of Making and Uses

The disclosure relates to a process of making an absorbent core 101comprising the steps of:

i. providing a mold comprising a 3D insert therein, said 3D insert beingthe inverse shape of the desired channels, wherein substantially theentire surface of the mold is in fluid communication with anunder-pressure source except for the 3D insert;ii. applying a first nonwoven web to said mold;iii. applying a three-dimensional absorbent material over at least aportion of said nonwoven;iv. applying a second nonwoven web directly or indirectly over thethree-dimensional absorbent material;v. optionally applying a bonding step to form a laminate comprising saidfirst nonwoven, said second nonwoven and said three-dimensionalabsorbent material therebetween;vi. optionally removing said laminate from the mold to form an absorbentcore comprising channels having the inverse shape of said 3D insert; andwherein at least for the duration of step iii the underpressure sourceis arranged to provide a vacuum force forcing said three-dimensionalabsorbent material around the 3D insert such to substantially evacuatethe surface thereof from three-dimensional absorbent material and formchannels substantially free of three-dimensional absorbent material.Such process has been found effective in creating channels substantiallyfree of three-dimensional absorbent material compared to processes usingembossing (i.e. creating channels of highly dense/packedthree-dimensional absorbent material) or material removal processes thatcomprise removing three-dimensional absorbent material from a pre-formedcore structure which inevitably results in the presence of somethree-dimensional absorbent material that may affect effective/uniformfluid distribution upon saturation thereof.

FIG. 15A and FIG. 15B illustrate an example of a mold comprising a 3Dinsert as described herein.

In an embodiment, the mold comprises a plurality of perforations oropenings across its surface typically forming channels arranged to be influid (preferably air) communication with the under pressure source.Preferably, the 3D insert is positioned above and/or over said moldsurface comprising a plurality of said perforations or openings and said3D insert being free of said perforations or openings and consists of asolid component that is not in fluid communication with the underpressure source.

Preferably, the 3D insert has a cross-sectional shape selected from thegroup consisting of square, rectangular, oval, semi-circular, andcombinations thereof.

More preferably, the 3D insert has the same or varying depth throughoutthe perimeter thereof.

In an embodiment, the 3D insert is 3D-printed, preferably made from amaterial selected from alumide, or is made from metal and formed bymilling or casting.

In a preferred embodiment, the bonding step comprises applying anadhesive on a surface of the second nonwoven web and joining said web tosaid first nonwoven web and/or three-dimensional absorbent material,preferably the adhesive being applied in continuous or discontinuousspaced apart stripes aligned with said channels such that the resultingcore laminate comprises adhesive rich and adhesive poor regions, whereinthe adhesive rich regions are substantially located along said channelsand the adhesive poor regions are located in areas of the core otherthan said channels. An advantage of this embodiment is to limit the riskof adhering absorbent material within the channels and to ratherdirectly bond the topsheet and backsheet nonwoven together at thesechannel locations.

In an embodiment, the adhesive is applied in zones across the width ofthe channels such to form zones, preferably alternating zones, ofdifferent bonding strength between the laminate. For example the firstnonwoven web may be bonded to the second nonwoven web on at least threezones along the width of the channel. Such arrangement may comprise afirst adhesive zone, a second adhesive zone and a third adhesive zone,the second adhesive zone being interposed between the first and thirdadhesive zones along the width of the channel (e.g. at an axis parallelto the core width and perpendicular to the longitudinal axis of thecore) wherein the bonding strength of the second adhesive zone isgreater than the bonding strength of the first and third adhesive zones.Examples of ways to achieve such stronger bonding strength in the secondzone include using higher amounts of adhesive in this zone, applyinggreater mechanical pressure on this zone, or utilizing a differentadhesive type, other ways are also contemplated provided a strongeradhesion between nonwoven webs results in such region.

In an embodiment the bonding strength in the first and third zones isless than the tensile force generated by the absorbent material locatedproximal to the channel upon wetting, such that the first and secondnonwoven webs may separate in said zones upon wetting; and wherein thebonding strength in the second zone is greater than the tensile forcegenerated by the absorbent material located proximal to the channel uponwetting, such that the first and second nonwoven webs may not separatein said zone upon swelling of the absorbent material and rather mayremain fixedly joined. An advantage of this arrangement is that in dryconditions a noticeable channel is visible from the topsheet side of thearticle and/or core providing broad channels that are further useful forchanneling more fluid particularly at initial/early discharge. Thisarrangement then further allows the bonding at the first and thirdregions to fail upon for example swelling of the SAP such to allow morevolume to be available for expansion thereof (and prevent earlysaturation or non-optimal absorption), with typically the second zoneresisting such expansion and thus providing integrity of the channelseven in wet state.

In a preferred embodiment the first nonwoven web and/or the secondnonwoven web, preferably the second nonwoven web, are elastic nonwovens(e.g. containing an elastic material such as Vistamaxx resin fromExxonMobil). An advantage of this embodiment is that the nonwoven webbetter and more easily wraps around the 3D insert upon application of avacuum and permits subsequent joining to the first nonwoven web at alocation corresponding to a position of the base of the 3D insert(opposite a protruding apex thereof). This has an advantage of limitingthe formation of fluid collection basins or sinks within the channels.

More preferably, the channels are formed substantially only by saidvacuum force and no additional mechanical action such as embossing.

In an embodiment, the adhesive is applied such that, when laminated, theadhered first and second nonwoven webs in the channel locations issubstantially flush with the non-adhered portions of the second nonwovenweb such to limit the formation of fluid retention pockets in theresulting laminated core. An advantage of this embodiment is to preventthe formation of pockets of fluid that may reduce comfort to thesubject.

The mold described herein above may be contained within thecircumference of a rotating drum apparatus, said drum apparatustypically comprising a plurality of said molds along its circumference.Said drum apparatus may be integrated within existing apparatuses forforming absorbent core laminates. An advantage of such a simplearrangement is that it allows for the formation of such novel absorbentcores in a simple and effective manner without considerable capitalinvestment to substantially change major parts of existing core formingequipment.

The disclosure also relates to the use of an absorbent core described inthe previous sections herein in an absorbent article described above,for improved liquid distribution compared to the same absorbent articlecomprising a core free of substantially interconnected channels.

The disclosure further relates to the use of an absorbent core describedin the previous sections herein in an absorbent article described above,for providing a tri-stage fluid acquisition typically comprising a firstfluid distribution at a first speed, a second fluid distribution at asecond speed and a third fluid distribution at a third speed, said firstspeed being greater or equal to said second speed and said third speedbeing less than said first speed and less than or equal to said secondspeed, preferably wherein the first fluid distribution is driven by thesubstantially interconnected channels, the second fluid distribution isdriven by a three-dimensional absorbent material comprised within thecore, and the third fluid distribution is driven by an amount of superabsorbent polymer dispersed within the three-dimensional absorbentmaterial. Without wishing to be bound by theory it is believed that thenovel cores described herein comprising the novel interconnected channelarrangement described, allows to achieve a unique and first in kinddistinct fluid distribution and absorption system whereby firstly thechannels provide for fast liquid distribution/evacuation from the regionof discharge, followed by further distribution from neighboring surfacesof the channels towards other portions of the core via thethree-dimensional absorbent material, and finally the super absorbentpolymer dispersed within the three-dimensional absorbent material whenpresented with fluid begins an absorption of said fluid whilst swellingsuch to permit the three-dimensional absorbent material to distributeand transfer more of said fluid to the super absorbent polymer.

The disclosure is further described by the following non-limitingexamples which further illustrate the disclosure, and are not intendedto, nor should they be interpreted to, limit the scope of thedisclosure.

EXAMPLES Example 1

FIGS. 5-8 representatively illustrate an example of a disposable diaper,as generally indicated at 20, according to the present disclosure.

As representatively illustrated in FIGS. 5-7, the diaper 20 defines afront waist region 22, a back waist region 24, a crotch region 26 whichextends between and connects the front and back waist regions 22 and 24,a pair of laterally opposed side edges 28, an interior surface 30 and anouter surface 32. The front waist region 22 comprises the portion of thediaper 20 which, when worn, is positioned on the front of the wearerwhile the back waist region 24 comprises the portion of the diaper 20which, when worn, is positioned on the back of the wearer. The crotchregion 26 of the diaper 20 comprises the portion of the diaper 20 which,when worn, is positioned between the legs of the wearer and covers thelower torso of the wearer.

The diaper 20 includes an outer cover 34, an absorbent chassis 36 and afastening system 50. The absorbent chassis 36 is configured to containand/or absorb any body exudates discharged from the wearer. Whereas, theouter cover 34 and fastening system 50 are configured to maintain thediaper 20 about the waist of the wearer, conceal the absorbent chassis36 from view, and provide a garment-like appearance. The diaper 20 mayfurther include leg elastics 96 and 98 and containment flaps 100 and102. It should be recognized that individual components of the diaper 20may be optional depending upon the intended use of the diaper 20.

As representatively illustrated in FIGS. 5-8, the laterally opposed sideedges 28 of the diaper 20 are generally defined by the side edges of theouter cover 34 which further define leg openings which may becurvilinear. The waist edges of the outer cover 34 also define a waistopening which is configured to encircle the waist of the wearer whenworn.

As representatively illustrated in FIGS. 5-8, the absorbent chassis 36of the diaper 20 is suitably connected to the outer cover 34 to providethe disposable diaper 20. The absorbent chassis 36 may be connected tothe outer cover 34 in manners well known to those skilled in the art.For example, the absorbent chassis 36 may be bonded to the outer cover34 using adhesive, thermal or ultrasonic bonding techniques known tothose skilled in the art. Alternatively, the absorbent chassis 36 may beconnected to the outer cover 34 using conventional fasteners such asbuttons, hook and loop type fasteners, adhesive tape fasteners, and thelike. The other components of the diaper 20 may be suitably connectedtogether using similar means.

Desirably, the absorbent chassis 36 is connected to the outer cover 34only at or adjacent the waist edges of the outer cover 34 therebycreating a front attached portion, a back attached portion and anunattached portion which extends between and connects the attachedportions. The unattached portion of the absorbent chassis 36 remainssubstantially unattached to the outer cover 34 and is generallyconfigured to fit between the legs of the wearer and at least partiallycover the lower torso of the wearer when in use. As a result, theunattached portion is generally the portion of the absorbent chassis 36which is configured to initially receive the body exudates from thewearer when in use.

In this manner, the absorbent chassis 36 is connected to the outer cover34 in such a manner to secure the chassis 36 in place while notadversely restricting the movement of the outer cover 34 in use.Alternatively, the absorbent chassis 36 may be attached to the outercover 34 along the entire longitudinal length of the absorbent chassis36 or any portion thereof or along only the outer periphery of theabsorbent chassis 36.

As representatively illustrated in FIGS. 5-8, the absorbent chassis 36according to the present disclosure may include a back sheet 38, a topsheet 40 which is connected to the backsheet 38 in a superposedrelation, and an absorbent core 42 which is located between the topsheet 40 and the back sheet 38.

The absorbent chassis 36 is generally conformable and capable ofabsorbing and retaining body exudates. The absorbent chassis 36 may haveany of a number of shapes and sizes. For example, as representativelyillustrated in FIGS. 5-8, the absorbent chassis 36 may be rectangular,I-shaped or T-shaped. The size and absorbent capacity of the absorbentchassis 36 should be compatible with the size of the intended wearer andthe fluid loading imparted by the intended use of the diaper 20.

The top sheet 40 of the absorbent chassis 36, as representativelyillustrated in FIGS. 5-8, suitably presents a bodyfacing surface whichis intended to be worn adjacent the body of the wearer and is compliant,soft feeling and nonirritating to the wearer's skin.

Further, the top sheet 40 may be less hydrophilic than the absorbentcore 42, to present a relatively dry surface to the wearer, and may besufficiently porous to be liquid permeable, permitting liquid to readilypenetrate through its thickness. A suitable top sheet 40 may bemanufactured from a wide selection of web materials, such as porousfoams, reticulated foams, apertured plastic films, natural fibers (forexample, wood or cotton fibers), synthetic fibers (for example,polyester or polypropylene fibers), or a combination of natural andsynthetic fibers. The top sheet 40 is suitably employed to help isolatethe wearer's skin from fluids held in the absorbent core 42 of theabsorbent chassis 36.

The top sheet 40 and back sheet 38 are generally adhered to one anotherso as to form a pocket in which the absorbent core 42 is located toprovide the absorbent chassis 36. The top sheet 40 and back sheet 38 maybe adhered directly to each other around the outer periphery of theabsorbent chassis 36 by any means known to those skilled in the art suchas adhesive bonds, sonic bonds or thermal bonds. For example, a uniformcontinuous layer of adhesive, a patterned layer of adhesive, a sprayedor meltblown pattern of adhesive or an array of lines, swirls or spotsof adhesive may be used to affix the top sheet 40 to the back sheet 38.It should be noted that both the top sheet 40 and the back sheet 38 neednot extend completely to the outer periphery of the absorbent chassis36. For example, the back sheet 38 may extend to the outer periphery ofthe absorbent chassis 36 while the top sheet 40 may be attached to theback sheet 38 inboard of the outer periphery of the absorbent chassis36, or more towards the longitudinal centerline of the diaper 20.

The absorbent core 42, as representatively illustrated in FIGS. 5-8, ispositioned between the top sheet 40 and the back sheet 38 to form theabsorbent chassis 36. The absorbent core 42 is desirably conformable andcapable of absorbing and retaining body exudates. The absorbent core 42may have any of a number of shapes and generally discrete layer withinthe matrix of hydrophilic fibers. Alternatively, the absorbent core 42may comprise a laminate of fibrous webs and high-absorbency material orother suitable means of maintaining a high-absorbency material in alocalized area.

As representatively illustrated in FIGS. 5-8, the absorbent chassis 36of the disposable diaper 20 may include a pair of containment flaps 100and 102 which are configured to provide a barrier to the lateral flow ofbody exudates. The containment flaps 100 and 102 may be located alongthe laterally opposed side edges of the absorbent chassis 36. Eachcontainment flap defines an attached edge 104 and an unattached edge106. Each of the containment flaps 100 and 102 may also include at leastone elongated elastic member 108 which is adhered to the unattached edge106 of the containment flap 100 and 102 and configured to gather theunattached edge 106 and form a seal against the body of the wearer whenin use. The containment flaps 100 and 102 may extend longitudinallyalong the entire length of the absorbent chassis 36 or may only extendpartially along the length of the absorbent chassis 36. When thecontainment flaps 100 and 102 are shorter in length than the absorbentchassis 36, the containment flaps 100 and 102 can be selectivelypositioned anywhere along the side edges 38 of the absorbent chassis 36.In a particular aspect of the disclosure, the containment flaps 100 and102 extend along the entire length of the absorbent chassis 36 to bettercontain the body exudates.

Each containment flap 100 and 102 is attached to the side edges 38 ofthe absorbent chassis 36 such that the containment flaps 100 and 102provide a barrier to the lateral flow of body exudates. The attachededge 104 of each of the containment flaps 100 and 102 is attached to theside edges 38 of the absorbent chassis 36 while the unattached edge 106remains unattached from the absorbent chassis 36 in at least the crotchregion 26 of the diaper 20. The attached edge 104 of the containmentflaps 100 and 102 may be attached to the absorbent chassis 36 in any ofseveral ways which are well known to those skilled in the art. Forexample, the attached edge 104 of the flaps 100 and 102 may beultrasonically bonded, thermally bonded or adhesively bonded to theabsorbent chassis 36. In a particular aspect, the unattached edge 106 ofeach of the containment flaps 100 and 102 remains unattached from theside edges 38 of the absorbent chassis 36 along substantially the entirelength of the unattached edge 106 to provide improved performance.

Alternatively, as representatively illustrated in FIGS. 4-7, thecontainment flaps 100 and 102 may be integral with the back sheet 38 ortop sheet 40 of the absorbent chassis 36.

Each containment flap 100 and 102 is also configured such that theunattached edge 106 of the containment flaps 100 and 102 tends toposition itself in a spaced relation away from the absorbent chassis 36toward a generally upright and perpendicular configuration, especiallyin the crotch region 26 when in use. As representatively illustrated inFIGS. 5-8, the unattached edge 106 of each containment flap 100 and 102is desirably spaced away from the absorbent chassis 36 when in usethereby providing a barrier to the lateral flow of body exudates.Desirably, the unattached edge 106 of each containment flap 100 and 102maintains a contacting relationship with the body of the wearer whilethe absorbent chassis 36 may be spaced away from the body of the wearerwhen in use. Typically, an elastic member 108 is attached to theunattached edge 106 of each containment flap 100 and 102 to maintain thespaced away relationship between the unattached edge 106 and theabsorbent chassis 36. For example, the elastic member 108 may beattached to the unattached edge 106 in an elastically contractiblecondition such that the contraction of the elastic member 108 gathers orcontracts and shortens the unattached edge 106 of the containment flap100 and 102.

The disposable diaper 20 of the different aspects of the presentdisclosure may further include elastics at the waist edges and sideedges 28 of the diaper 20 to further prevent the leakage of bodyexudates and support the absorbent chassis 36. For example, asrepresentatively illustrated in FIGS. 5-8, the diaper 20 of the presentdisclosure may include a pair of leg elastic members 96 and 98 which areconnected to the laterally opposed side edges 28 in the crotch region 26of the diaper 20. The leg elastics 96 and 98 are generally adapted tofit about the legs of a wearer in use to maintain a positive, contactingrelationship with the wearer to effectively reduce or eliminate theleakage of body exudates from the diaper 20.

The absorbent article illustrated in FIG. 9 to FIG. 12 generallyrepresents a training pant. The absorbent article 10. The longitudinaldirection 48 generally extends from the front of the absorbent articleto the back of the absorbent article. Opposite to the longitudinaldirection 48 is a lateral direction 49. The absorbent article 10includes a chassis 12 that is comprised of a front portion 22, a backportion 24, and a crotch portion 26. Positioned within the crotchportion 26 and extending from the front portion 22 to the back portion24 is an absorbent core 28.

The absorbent article 10 defines an interior surface that is configuredto be placed adjacent to the body when being worn. The absorbent article10 also includes an exterior surface opposite the interior surface. Thefront and back portions 22 and 24 are those portions of the articlewhich, when worn, partially cover or encircle the waist or mid-lowertorso of the wearer. The crotch portion 26, on the other hand, isgenerally positioned between the legs of the wearer when the absorbentarticle has been donned.

As shown in FIG. 9, the absorbent article further includes a first sidearea 30 and a second side area 34. The side areas 30 and 34 connect thefront portion 22 with the back portion 24. The side areas 30 and 34 canalso help define the leg openings and the waist opening.

The side areas 30 and 34, in one embodiment, can be made from astretchable or extensible material. In one embodiment, for instance, theside areas 30 and 34 are made from an elastic material. The side areasserve to form a snug but comfortable fit around the torso of a wearer.The side areas 30 and 34 can also allow for accommodating differenttorso circumferences.

As shown, each of the side areas 30 and 34 can be made from multiplestretchable panels. For instance, in the embodiment shown in FIG. 9, theside areas 30 and 34 are each made from two panels. As shown, forinstance, the side area 30 includes a first panel 31 and a second panel33. Similarly, the second side area 34 includes a first panel attachedto a second panel 37. The panels 31 and 33 of the first side area 30 areattached together to form a first vertical attachment area 41 while thepanels 35 and 37 of the second side area 34 are attached together alonga second vertical attachment area 43. The attachment between the panelscan be permanent or can be unfastenable and refastenable. When thepanels are releasably attached together, for instance, any suitablemechanical fastener may be used. For example, in one embodiment, thepanels may be releasably attached together using any suitable adhesivefastener, cohesive fastener, mechanical fastener, or the like. Suitablemechanical fastening elements can be provided by interlocking geometricshaped materials, such as hooks, loops, bulbs, mushrooms, arrowheads,balls on stems, male and female mating components, buckles, snaps, andthe like.

In the embodiment illustrated in FIGS. 9-12, the panels 31 and 33 thatcomprise the first side area 30 and the panels 35 and 37 that comprisethe second side area 34 are joined together using a fastening system 80that includes laterally opposite first fastening components 82 adaptedfor refastenable engagement to corresponding second fastening components84. For instance, in one embodiment, a front or outer surface of each ofthe fastening components 82, 84 includes a plurality of engagingelements. The engaging elements of the first fastening components 82 areadapted to repeatably engage and disengage corresponding engagingelements of the second fastening components 84 to releasably secure theabsorbent article in its 3-dimensional configuration.

In an embodiment for instance, the first fastening components 82 includeloop fasteners and the second fastening components 84 includecomplementary hook fasteners. Alternatively, the first fasteningcomponents 82 may include hook fasteners and the second fasteningcomponents 84 may be complementary loop fasteners. In another aspect,the fastening components 82 and 84 can be interlocking similar surfacefasteners, or adhesive or co-adhesive fastening elements such as anadhesive fastener and an adhesive-receptive landing zone or material.

As described above, in an alternative embodiment, the panels thatcomprise the side areas may be permanently attached together. Forinstance, referring to FIG. 10, an alternative embodiment of anabsorbent article 10 is shown. Like reference numerals have been used toindicate the same or similar elements. As shown, the absorbent article10 in FIG. 10 includes a first side area 30 comprised of panels 31 and33 and a second side area 34 comprised of panels 35 and 37. The firstside panel 30 defines a first vertical attachment area 41 where thepanels 31 and 33 are permanently bonded together. Similarly, the secondside area 34 defines a second vertical attachment area 43 where thepanels 35 and 37 have been permanently attached together. In thisembodiment, the vertical attachment areas comprise seams. The seams, forinstance, can be constructed in any suitable manner. For instance, thevertical seam may comprise a lap seam, a butt seam, or any othersuitable configuration. The seams can be formed by attaching the panelstogether using any suitable method or technique. For example, the panelscan be permanently attached together using ultrasonic bonding, thermalbonding, adhesive bonding, and/or pressure bonding. In still anotheralternative embodiment, the separate panels can be sewn together.

As shown in FIGS. 9 and 10 when the side areas 30 and 34 are in afastened position, the front and back portions 22 and 24 are connectedtogether to define a 3-dimensional pants configuration having a waistopening 50 and a pair of leg openings 52. The side areas 30 and 34, uponwearing of the absorbent article 10, thus include the portions of thearticle which are positioned on the hips of the wearer and, in oneembodiment, define the upper edge of the leg openings 52.

As described above, the chassis 12 can, in one embodiment, include anouter cover 40 and a top sheet 42 as shown particularly in FIGS. 11 and12. Depending upon the embodiment, the outer cover 40 and the top sheet42 can comprise a unitary single-piece of material or can comprisemultiple pieces of material bonded together. The top sheet 42 may bejoined to the outer cover 40 in a superimposed relation using, forinstance, adhesives, ultrasonic bonds, thermal bonds, pressure bonds orother conventional techniques. The top sheet 42 may suitably be joinedto the outer cover 40 along the perimeter of the chassis 12 to form afront waist seam 62 and a back waist seam 64. The top sheet 42 may alsobe joined to the outer cover 40 to form a pair of side seams 61. The topsheet 42 can be generally adapted, i.e., positioned relative to theother components of the absorbent article 10, to be disposed toward thewearer's skin when donned. As described above, the chassis 12 alsoincludes the absorbent core 28 which is disposed between the outer cover40 and the top sheet 42 for absorbing liquid body exudates exuded by thewearer.

In accordance with the present disclosure, the absorbent article 10further includes one or more extended waistbands that are intended toimprove product appearance, to improve fit, and/or make the product feelmore like real underwear. As shown in the figures, for instance, theabsorbent article 10 can include a back waistband 56, a front waistband54, or can include both a front waistband and a back waistband. Asshown, for instance, the back waistband 56 extends over the entire backportion 24 of the chassis 12 and terminates at each end on the sideareas 30 and 34.

It is supposed that the present disclosure is not restricted to any formof realization described previously and that some modifications can beadded to the presented example of fabrication without reappraisal of theappended claims. For example, although the above example makes referenceto the embodiments of FIG. 5 to FIG. 8, similar structures may be foundin other embodiments as illustrated in FIG. 9 to FIG. 12, and furtherfeminine care articles such as those of FIG. 13 and FIG. 14. Moreover,although the example and figures relate to baby diapers and pants, thesame remains applicable to incontinence diapers and pants for adultsalbeit with some structural alterations which would be apparent to aperson skilled in the art.

Example 2

Referring to FIG. 13 and FIG. 14, the absorbent articles may be of thesanitary napkin or panty liner type.

The structure of the napkin or panty liner may vary in construction aslong as a core as described herein is used. Generally such napkin orpanty liner include a laminate comprising a backsheet, an absorbent core(with or without three-dimensional absorbent material) and optionally aliquid distribution layer (ADL) positioned between the topsheet and theabsorbent core.

As shown in FIG. 14 the interconnected channel 106 may be in a pluralityand be substantially concentric with respect to each other and may beinverse in shape about an axis parallel to the width of the core.Although such pattern is illustrated as an example for use in a core fora sanitary napkin or a panty liner 300, such shape may be equallyapplied and is encompassed in the teaching of cores for diapers andpants (whether for babies or incontinence for adults) herein.

1.-14. (canceled)
 15. A method of tri-stage fluid distribution in anabsorbent article containing a core having substantially interconnectedchannels, the method comprising: distributing a first fluid at a firstspeed, distributing a second fluid at a second speed and distributing athird fluid at a third speed, said first speed being greater or equal tosaid second speed and said third speed being less than said first speedand less than or equal to said second speed, wherein the first fluiddistribution is driven by the substantially interconnected channels, thesecond fluid distribution is driven by a three-dimensional absorbentmaterial comprised within the core, and the third fluid distribution isdriven by an amount of super absorbent polymer dispersed within thethree-dimensional absorbent material.
 16. A process of making anabsorbent core (101) comprising the steps of: i. providing a moldcomprising a 3D insert therein, said 3D insert being an inverse shape ofone or more substantially interconnected channels, wherein substantiallythe entire surface of the mold is in fluid communication with anunder-pressure source except for the 3D insert; ii. applying a firstnonwoven web to said mold; iii. applying a three-dimensional absorbentmaterial over at least a portion of said nonwoven; iv. applying a secondnonwoven web directly or indirectly over the three-dimensional absorbentmaterial; v. optionally applying a bonding step to form a laminatecomprising said first nonwoven, said second nonwoven and saidthree-dimensional absorbent material therebetween; vi. optionallyremoving said laminate from the mold to form an absorbent corecomprising one or more substantially interconnected channels having aninverse shape of said 3D insert; and characterized in that at least forthe duration of step iii the underpressure source is arranged to providea vacuum force forcing said three-dimensional absorbent material aroundthe 3D insert such to substantially evacuate the surface thereof fromthree-dimensional absorbent material and form one or more substantiallyinterconnected channels substantially free of three-dimensionalabsorbent material.
 17. The process according to claim 16 wherein the 3Dinsert has a cross-sectional shape selected from the group consisting ofsquare, rectangular, oval, semicircular, and combinations thereof. 18.The process according to claim 16 wherein the 3D insert has the samedepth throughout the perimeter thereof.
 19. The process according toclaim 16 wherein the 3D insert has varying depth throughout theperimeter thereof.